Spindle motor

ABSTRACT

In a spindle motor in which teeth portions of a stator core formed by laminating magnetic plates are bent in order to increase the number of turns of the stator windings, a gap in the teeth portions between the magnetic plates is avoided and a precise attractive force adjustment becomes possible. The stator core is bent such that its teeth portions faces a surface of a rotor magnet at right angles, and the teeth portions and salient pole arm portions around which windings are wound are substantially parallel to each other. The salient pole arm portions locate approximately halfway between a lower surface of a hub and an upper surface of a base. Further, a thickness of a magnetic plate is set to be 0.5 to 0.9 times that of other portions.

This is a Rule 1.53(b) Divisional application of Ser. No. 11/293,078,filed Dec. 5, 2005

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a spindle motor for rotating magneticdiscs, optical discs and the like, and a brushless motor having astructure similar to that of the spindle motor.

2. Description of the Related Art

In recent years, electronic equipment is becoming smaller and smaller.Thus, there is a growing demand for hard disc drives (HDDs) incorporatedtherein to become smaller and thinner. For example, until few years ago,HDDs for discs having a diameter of 3.5 inches or 2.5 inches had beenused commonly. However, recently, HDDs for discs having a diameter of1.8 inches or smaller, that is, 1 inch or 0.85 inches are becomingpopular. When the disc diameter is reduced, motors such as spindlemotors, brushless motors and the like for rotating the disc also have tobecome smaller and thinner. A reduction in size and thickness of motorsis required not only in the field of HDDs but also in many other fields.As HDDs become faster, smaller and thinner, motors are required torotate with a higher precision, lower vibration, and less noise. Thus,the type of a bearing used in motors is shifted from a conventional ballbearing to a hydrodynamic bearing. The hydrodynamic bearings float androtate rotors without being in contact therewith by using a pumpingforce generated by fluid through a dynamic pressure generating groove.Therefore, it is necessary to pull the rotor to a stator in an axialdirection with a certain force in order to prevent the rotor from movingin an axial direction and changing its position when a position of themotor is changed. In general, such an attractive force is obtained bytwo means.

The first means is a method of generating an attractive force between arotor and a stator by utilizing a magnetic force applied by a rotormagnet to the stator by providing a magnetic member on a stator side ofthe motor or forming the stator side of the motor of a magneticmaterial.

The second means is a method of obtaining an attractive force in anaxial direction by shifting magnetic centers of a rotor magnet and astator core of the motor in the axial direction such that a magneticforce of the rotor magnet is generated to the stator side.

In general, the former means is used to obtain most of an attractiveforce and the latter means is used to achieve fine adjustment of theattractive force. If the attractive force is small, the rotor floats bya large amount. The rotor may float beyond a permissible limit of anupward movement in the bearing and come into contact with othercomponents. An anti-vibration property of the whole device may alsodeteriorate. If the attractive force is large, the rotor floats by asmall amount. When an amount of the oil is decreased in the later stageof the life of the bearing, the life may be shortened due to a bearingcontact. In addition, vibration and noise of a spindle motor are alsoaffected by the shift length of the magnetic centers.

Therefore, for a spindle motor employing a fluid bearing, an attractiveforce has to be adjusted and designed more precisely.

A brushless spindle motor, which is a first conventional example of amotor having a reduced size and thickness, will be described withreference to FIG. 13.

FIG. 13 is a cross-sectional view of the first conventional example, abrushless motor of an external rotor type described in Japanese PatentGazette No. 3052540. In FIG. 13, ball bearings 106 are provided in abearing support 104 a in a central portion of a housing 104 having aplate-like shape. A shaft 101 with a rotor yoke 102 fixed thereto isfitted into a hole defined by inner ring 107 of the ball bearings 106.On an inner surface of the outer peripheral portion of the rotor yoke102, a rotor magnet 103 is provided.

A stator core 108 of the stator is provided on the housing 104. Thestator core 108 has projecting teeth portions (salient pole teethportions) 108 a in its outer peripheral portion as shown in a plain viewof FIG. 14. The stator core 108 is attached to the housing 104 such thatthe projecting teeth portions 108 a oppose the rotor magnet 103. Thestator core 108 is formed by laminating multiple layers of thin magneticplates punched into the shape shown in FIG. 14. A conducting wire iswound around salient pole arm portions 108 b of the stator core 108 toform windings 109. In the stator core 108 of FIG. 14, winding 109 isformed for each of six salient pole arm portions 108 b. The six windings109 are connected as Y connection or Δ connection, for example, in thecase of a three-phase motor. When a current flows through the windings109, an electromagnetic force is generated between the stator core 108and the rotor magnet 103, causing the rotor yoke 102 and the shaft 101to rotate in a predetermined direction.

In order to obtain a brushless motor with a high torque, generally, itis necessary to increase a magnetic force of the rotor magnet 103, orthe number of turns of the respective windings 109. However, in thestructure of FIG. 13, the number of turns can be increased only to anextent that the lower end surfaces of the windings 109 come into contactwith an insulating plate 105, which is a print substrate or the likeprovided on an upper surface of the housing 104. In such a state, aspace 111 between the rotor yoke 102 and an upper surface of thewindings 109 remains a spare space which is not fully utilized.

Japanese Patent Gazette No. 3052540 discloses a second conventionalexample obtained by improving the brushless motor shown in FIG. 13 tomake full use of the space 111 between the rotor yoke 102 and the uppersurfaces of the windings 109. FIG. 15A is a cross-sectional view of abrushless motor of the second conventional example. In FIG. 15A, thesame elements as those shown in FIG. 13 are denoted by the samereference numerals, and the descriptions thereof are omitted.

In the brushless motor shown in FIG. 15A, the shape of a stator core 118is different from that of the stator core 108 of the first conventionalexample. Specifically, the stator core 118 includes salient pole armportions 118 b and projecting teeth portions 118 a which have the sameplanar shape as those of the salient pole arm portions 108 b and theprojecting teeth portions 108 a of FIG. 14 but are different in that theprojecting teeth portions 118 a are bent downward in boundary portionsbetween the salient pole arm portions 118 b and the projecting teethportions 118 a as shown in FIG. 15. Since the projecting teeth portions118 a are bent downward, the entire stator core 118 can be moved awayfrom the housing 104 in an upward direction and a gap between the lowerend surface of the stator core 118 and the housing 104 can be madelarger with the tips of the projecting teeth portions 118 a facing therotor magnet 103. With such a structure, the number of turns of therespective windings 119 can be larger than the number of turns of thewindings 109 of the first conventional example. As a result, the space111 between the stator core 118 and the rotor yoke 102 can beeffectively used to achieve a stator having the windings 119 with largenumber of turns without changing the size of the entirety of thebrushless motor.

The second conventional example of the brushless motor has following twoproblems.

The first problem is as follows. Since the projecting teeth portions(salient pole teeth portions) 118 a of the stator core 118 are bent, thecross sections of the projecting teeth portions 118 a of multiple coresheets forming the stator core 118 are not perpendicular but diagonal tothe inner peripheral surface of the rotor magnet 103. When theprojecting teeth portions 118 a oppose to the rotor magnet 103diagonally, an air gap between the rotor magnet 103 and the projectingteeth portions 118 a expands substantially. Thus, a magnetic resistanceis increased and an operational point of the rotor magnet 103 islowered. Torque constant Kt (a value represented by a ratio of torque tocurrent) is lowered.

Further, a position of the magnetic center of the stator core isdifficult to be determined. A variance in the magnetic centers among themotors becomes large. Thus, there is large variance in attractive forcesand motor properties such as an amount of floating and the life are notstabilized.

The second problem is due to a method for producing the stator. In orderto produce the stator core 118 having the bent projecting teeth portions118 a, usually, core sheets are first laminated and then the laminatedcore sheets are collectively subjected to a bending working, or coresheets are first formed into a shape shown in FIG. 14 by a press working(punching), the projecting teeth portions 118 a are bent by a bendingworking (process by a plastic deformation), and then the bent coresheets are laminated to produce the stator core 118. When the statorcore 118 is produced by the former method, a large pressing force may berequired depending upon the number of laminated layers. When the statorcore 118 is produced by the latter method, the core sheets do not adhereclosely to each other in the tip portions of the projecting teethportions 118 a, and small gaps 122 may be generated between the coresheets as shown in FIG. 15B. Thus, when the current flows through thewindings 119, the projecting teeth portions 118 a may vibrate,generating a noise. Furthermore, leakage flux from the stator core 118increases and the magnetic property deteriorates. This increases powerloss. It is also difficult to predict where the magnetic center of thestator core is, and a variance in the magnetic centers among the motorsbecomes large. Therefore, there is a large variance in attractive forcesand the motor properties such as an amount of floating, the life, andthe like are not stabilized.

The gaps between the projecting teeth portions 118 a of the core sheetsdescribed above are generated for the following reasons. When theprojecting teeth portions 118 a of the plurality of core sheets are bentto form the stator core 118, for example, a flexural center C is set ina lower portion of the stator core 118 as shown in FIG. 16. Bent areas120 of five core sheets 118 g, 118 h, 118 i, 118 j, and 118 k are variedas shown in FIG. 16 with the largest being the bent area 120 g of thecore sheet 118 g and the smallest being the bent area 120 k of the coresheet 118 k. If the core is formed as described above, no gap is formedbetween the laminated core sheets 118 g through 118 k. However, forvarying the bent areas of the core sheets 118 g through 118 k, onebending mold is required for each of the core sheets 118 g through 118k. If one mold is used for all the core sheets, a large strong bendingworking machine is required and a process cost is increasedsignificantly.

Usually, the core sheets 118 g through 118 k are formed with one mold.Thus, the core sheets having the same bent area are laminated. FIG. 17shows a laminate of a plurality of core sheets 125 g through 125 kformed with one mold. FIG. 17 is a partial cross-sectional view oflaminated core sheets 125 g, 125 k, 125 i, 125 j, and 125 k. As shown inFIG. 17, the core sheets 125 g through 125 k have planar portions 126and bent portions 127. The bent portions 127 are formed by bending theright end portions of the core sheets 125 g through 125 k which haveoriginally had a plate shape by, for example, thirty degrees with onemold. As shown in FIG. 17, when it is tried to laminate the core sheets125 g through 125 k with the internal diameter sides of the planarportions 126 thereof being aligned and adhering closely to each other,the bent portions 127 of adjacent core sheets, for example, the coresheets 125 g and 125 h, overlap each other as shown by a shaded overlapportion 128. Actually, the core sheets 125 g and 125 h cannot overlapeach other in the overlap portion 128. Thus, when the core sheets 125 gand 125 h are adhered closely to each other in the planar portions 126,they press each other in the bent portions 127 and a gap is generated intip portions as shown in FIG. 15B. The same is also true of other coresheets 125 i through 125 k.

SUMMARY OF THE INVENTION

An object of the present invention is to provide a spindle motor havinga stator core with its salient pole teeth portions being bent but no gapis produced between the salient pole teeth portions facing a rotormagnet.

According to one aspect of the present invention, there is provided aspindle motor comprising: a rotor magnet supported by a hydrodynamicbearing device so as to be rotatable; a stator core formed by laminatinga plurality of thin magnetic material plates which have salient poleteeth portions facing the rotor magnet with a predetermined gapinterposed therebetween and salient pole arm portions which areconnected to the salient pole teeth portions and around which windingsare wound; and windings wound around the salient pole arm portions ofthe stator core, wherein the thin plates of the magnetic material of thestator core have the salient pole teeth portions facing an opposingsurface of the rotor magnet substantially perpendicularly, being bent atbent portions between the salient pole teeth portions and the salientpole arm portions such that the salient pole teeth portions and thesalient pole arm portions are substantially parallel, and a thickness ofthe bent portions of the thin plates is made thinner than that of otherportions.

According to the present invention, since bent core sheets (thinmagnetic plates) are laminated to form a stator core, salient pole teethportions of the stator core face a surface of the rotor magnetsubstantially perpendicularly while keeping winding space sufficiently.Thus, magnetic force lines of the rotor magnet pass through the statorcore at right angles and the magnetic force of the rotor magneteffectively influence rotational power. In bent portions, a thickness ofthe core sheet is made thinner than that of other portions. Thus, whenthe stator core is formed by laminating the core sheets, the tipportions of the salient pole teeth portions do not spread out and no gapis generated between the core sheets.

According to another aspect of the present invention, there is provideda spindle motor comprising: a rotor magnet supported by a hydrodynamicbearing device so as to be rotatable; a stator core formed by laminatinga plurality of thin magnetic material plates which have salient poleteeth portions facing the rotor magnet with a predetermined gapinterposed therebetween, salient pole arm portions which are connectedto the salient pole teeth portions, and a yoke portion connected to thesalient pole arm portions and fixed to a base; and windings wound aroundthe salient pole arm portions of the stator core, wherein the thinplates of the magnetic material of the stator core have the salient poleteeth portions facing an opposing surface of the rotor magnetsubstantially perpendicularly, being bent at first bent portions betweenthe salient pole teeth portions and the salient pole arm portions suchthat the salient pole teeth portions and the salient pole arm portionsare substantially parallel, and a thickness of the first bent portionsof the thin plates is made thinner than that of other portions, and thethin plates are bent at second bent portions between the yoke portionsand the salient pole arm portions such that the yoke portion and thesalient pole arm portions are substantially parallel, and a thickness ofthe second bent portions of the thin plates is made thinner than that ofother portions.

According to the present invention, the stator core is formed bylaminating core sheets bent at first bent portions and second bentportions. Since the core sheets are bent at the first bent portions, thesalient pole teeth portions face a surface of a rotor magnetsubstantially perpendicularly. Thus, magnetic force lines of the rotormagnet pass through the stator core at right angles and the magneticforce of the rotor magnet effectively influences rotational power.Further, since the core sheets are bent at the second bent portions, thesalient pole arm portions can be set at a desirable position to maximizethe number of turns of the coil. In the first and second bent portions,a thickness of the core sheet is made thinner than that of otherportions. Thus, when the stator core is formed by laminating the coresheets, the tip portions of the yoke portions and the salient pole teethportions do not spread out and no gap is generated in yoke portions andthe salient pole teeth portions between the core sheets.

According to the present invention, a stator core is bent in bentportions between salient pole arm portion around which windings arewound and salient pole teeth portions facing a rotor magnet. With such astructure, the salient pole arm portions can be disposed at anapproximately halfway between the base and the hub. In this way, aspindle motor having an increased number of turns of the windings woundaround the salient pole arm portions and a high torque can be achieved.

In the bent portions, the stator core is bent such that the salient poleteeth portions and the salient pole arm portions are parallel to eachother. Thus, the salient pole teeth portions face a surface of themagnet substantially perpendicularly. Thus, magnetic force lines of therotor magnet pass through the stator core at right angles and themagnetic force of the rotor magnet effectively influences rotationalpower.

Further, since a thickness of the stator core sheet forming the statorcore in the bent portions is made thinner than that of other portions,no gap is generated in the salient pole teeth portions between thestator core sheets adjacent to each other when the stator core sheetspressed and bent with one mold are laminated. The magnetism propertydoes not deteriorate, and no vibration and noise is generated.

Moreover, the position of the magnetism center of the stator corebecomes easy to be set. A variance in the magnetism centers among themotors also becomes small. This enables an accurate adjustment ofattractive forces.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a spindle motor according toEmbodiment 1 of the present invention.

FIG. 2 is a plain view of a stator core of the spindle motor accordingto Embodiment 1 of the present invention.

FIG. 3A is a plain view of a stator core sheet forming the stator coreof the spindle motor according to Embodiment 1 of the present invention;and FIG. 3B is a cross-sectional view cut along line IIIb-IIIb shown inFIG. 3A.

FIG. 4A is a partial plain view of the stator core sheet; FIG. 4B is across-sectional view cut along line IVb-IVb in FIG. 4A; FIG. 4C is across-sectional view showing bent portions 17 of FIG. 4B being thinned;and FIG. 4D is a cross-sectional view showing bent portions 17 of FIG.4C being bent.

FIG. 5 is a cross-sectional view of the stator core according toEmbodiment 1.

FIG. 6A is a partial plain view of the stator core sheet same as FIG.4A; FIG. 6B is a cross-sectional view cut along line VIb-VIb in FIG. 6A;FIG. 6C is a cross-sectional view showing the stator core sheet havingboth ends being held by clamping jigs 22 and 23; and FIG. 6D is across-sectional view showing the stator core sheet with the bentportions 17 being bent by moving the clamping jigs 22 and 23 in avertical direction.

FIGS. 7A through 7C are graphs showing the relationship between arotation angle of the hub and a torque.

FIG. 8 is a cross-sectional view of the spindle motor according toEmbodiment 2 of the present invention.

FIG. 9A is a plain view of a stator core sheet of the spindle motoraccording to Embodiment 2 of the present invention; FIG. 9B is across-sectional view cut along line IXb-IXb shown in FIG. 9A.

FIG. 10 is a cross-sectional view of the spindle motor according toEmbodiment 3 of the present invention.

FIG. 11 is a graph showing the relationship between the value of α andKt (torque constant).

FIG. 12 is a graph showing the relationship between the value of α and anoise.

FIG. 13 is a cross-sectional view of a spindle motor of a firstconventional example.

FIG. 14 is a plain view of a stator core of the spindle motor of a firstconventional example.

FIG. 15A is a cross-sectional view of a spindle motor of a secondconventional example; and FIG. 15B is a cross-sectional view of thestator core of the spindle motor of the second conventional example.

FIG. 16 is a partial cross-sectional view showing an exemplary bendingworking for the stator core of the second conventional example.

FIG. 17 is a partial cross-sectional view showing another example ofbending working for the stator core of the second conventional example.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, preferred embodiments of a spindle motor according to thepresent invention will be described with reference to FIGS. 1 through12.

Embodiment 1

FIG. 1 is a cross-sectional view of a spindle motor of an external rotortype according to Embodiment 1 of the present invention. As shown inFIG. 1, a base 4 which is a fixed portion of the spindle motor has abearing support 4 a of a tubular shape in its central portion. A bearingunit 5 is fixed into a hole of the bearing support 4 a. The bearing unit5 is a hydrodynamic bearing device of an axis-rotation type and supportsa shaft 8 so as to be rotatable. To the shaft 8, a hub 6 having aplate-like shape is attached.

There are two types of hydrodynamic bearing devices: an axis-rotationtype and an axis-fixed type. Both types can be applied to Embodiment 1.A radial bearing and a thrust bearing of the hydrodynamic bearingdevices may have structures as described below. In the radial bearing, asleeve is fitted to an outer periphery of an axis with a predeterminedgap interposed therebetween, and a lubrication fluid is filled in thegap between the axis and the sleeve. A dynamic pressure groove is formedon at least one of the axis and the sleeve. In the thrust bearing, aflange member having a diameter larger than an axis diameter (or a rigidbody having a flange function) is fixed to or integrally formed with atleast one end of the axis. A lubrication fluid is filled in a gapbetween at least one end surface of the flange member in an axialdirection and the end surfaces of the sleeve. A dynamic pressure grooveis formed on at least one of the axis and the sleeve. In anotherstructure of the thrust bearing, a flange body 26 having a diameterlarger than an axis diameter or a rigid body having a flange function isfixed to or integrally formed with at least one end of the shaft 8. Alubrication fluid (not shown) is filled in a gap between at least oneend surface of the flange member 26 in an axial direction and a thrustplate 27 blocking the sleeve or a blocking bottom surface of the sleeve.A dynamic pressure groove is formed on at least one of the axis and thesleeve. In yet another type of the structure, a lubrication fluid isfilled in a gap between one of end surfaces of the axis and the thrustplate blocking the sleeve or the blocking end surface of the sleeve, anda dynamic pressure groove is formed on at least one of the axis and thesleeve. The flange body may be a part of a component which has otherfunctions. The structure in which the dynamic pressure groove has acertain angle to the axial direction and a bearing serves as both theradial bearing and the thrust bearing may also be used.

For example, a magnetic disc or an optical disc is attached to a discreceiving surface 6 a of the hub 6. A rotor magnet 9 to be a rotor ofthe spindle motor is attached to an internal wall surface of an outerperiphery of the hub 6. If the base 4 is formed of a non-magneticmaterial, an attractive plate 19 is provided on an upper surface of thebase 4 where it faces the rotor magnet 9. The attractive plate 19 isformed of a magnetic material, and attracts the hub 6 in a downwarddirection with a magnetic force of the rotor magnet 9 such that avariance in the position of the rotor in an axial direction ismaintained within a certain range irrespective of a change in theposition of the spindle motor.

A stator core 12 having a salient pole shape is provided on an outerperipheral portion 11 of the bearing support 4 a of the base 4. As shownin a plain view of FIG. 2, the stator core 12 includes a yoke portion13, a plurality of salient pole arm portions 14 protruding from the yokeportion 13 in a radial direction, and teeth portions (salient pole teethportions) 15 integrally formed with tip portions of the salient pole armportions 14. The stator core 12 may be formed by, for example,laminating five layers of stator core sheets 12 a. The stator coresheets 12 a are formed by, for example, punching thin magnetic materialplates each having a thickness of 0.2 mm into a shape shown in FIG. 3A.As shown in FIG. 3B which is a cross-sectional view cut along lineIIIb-IIIb in FIG. 3A, the stator core sheet 12 a is bent along bendinglines 14 a indicated by a broken line in the salient pole arm portions14 to have a hill fold, and is bent along bending lines 14 b indicatedby broken lines in a border between the salient pole arm portions 14 andthe teeth portions 15 to have a valley fold. Bending directions andbending angles are set such that the yoke portion 13 and the teethportions 15 are substantially parallel to each other when the statorcore sheet 12 a is bent along the bending lines 14 a and 14 b. With thisstructure, in the spindle motor of Embodiment 1, the teeth portions 15of the stator core 12 face the surface of the rotor magnet 9 at rightangles. Thus, an air gap between the stator core 12 and the rotor magnet9 does not relatively expand and a magnetic force of the rotor magnet 9can be effectively utilized.

In the spindle motor according to Embodiment 1, a thickness (platethickness) of bent portions 17 between the bending lines 14 a and 14 bof the salient pole arm portions 14 of the stator core sheet 12 a shownin FIG. 3 is made thinner than that of other portions as described belowin detail.

FIG. 4A is a partial plain view showing only one of the salient pole armportions 14 and the teeth portions 15 of the stator core sheet 12 a ofFIG. 3. FIG. 4B is a cross-sectional view cut along line IVb-IVb in FIG.4A. The plate thickness of the stator core sheet 12 a is represented by“t”. A bent portion 17 between the bending lines 14 a and 14 b of thestator core sheet 12 a punched into the shape of FIG. 4A is compressedby, for example, press working so as to have a thinner plate thicknessas shown in FIG. 4C. The thinned plate thickness is represented by α-t.α is a value within the range of 0.5 to 0.9. Next, as shown in FIG. 4D,the stator core sheet 12 a is bent along the bending lines 14 a and 14 bto complete the process. Five layers of the stator core sheets 12 aobtained by the process illustrated in FIGS. 4A through 4D are laminatedto obtain the stator core 12 shown in FIG. 5.

In the stator core 12 of Embodiment 1, the plate thickness of the bentportions 17 of the stator core sheets 12 a is made thinner than that ofother portions so that an overlap portion of the stator core sheets 12 acorresponding to the overlap portion 128 of FIG. 17 can be removed. As aresult, as shown in FIG. 5, even when a plurality of the stator coresheets 12 a are laminated and adhered closely to each other in theirplanar portions, no gap is generated in the teeth portions 15 betweenthe stator core sheets 12 a adjacent to each other. In the stator coresheet 12 a shown in FIG. 5, the plate thickness is made thin to anextent that gaps 17 a are generated in the bent portions 17 between thestator core sheets 12 a adjacent to each other. When the plate thicknessof the stator core sheets 12 a is represented by t and the thickness ofthe central portions of the bent portions 17 is represented by α-t (α isa value of 0.5 or higher and 0.9 or lower), if the value of α is higherthan 0.9, it is inevitable that a gap is generated in the teeth portions15 between the stator core sheets 12 a adjacent to each other. If thevalue of α is below 0.5, magnetism saturation may occur due to adecrease in cross sections of the bent portions 17. This may cause Ktvalue to decrease and also vibration and noise to be generated. Thepresent inventors tried different values of α to study the results, andconfirmed that preferable results can be achieved when the value of α iswithin the range of 0.5 to 0.9. More preferably, the value of α iswithin the range of 0.7 to 0.8.

FIG. 11 is a graph showing the relationship between the value of α andtorque constants Kt (%). In FIG. 11, torque constant Kt when the statorcore is not bent and the value of α is 1 is assumed to be 100%(reference value). As can be seen from FIG. 11, Kt is 95% or higher whenthe value of α is within the range of 0.5 to 0.9. Deviation from thereference value is small.

FIG. 12 is a graph showing the relationship between the value of α and anoise (dB). As can be seen from FIG. 12, a noise hardly increases whenthe value of α is within the range of 0.5 to 0.9.

The plate thickness of the bent portions 17 can be made thinner usingmethods other than the press working. In the example shown in FIG. 6,both ends of the bent portions 17 are held with clamping jigs 22 and 23as shown in FIG. 6C and they are moved in vertical direction as shown inFIG. 6D. In this way, the bent portions 17 are drawn out to have athinner plate thickness, and a bend working is performed at the sametime.

The present inventors have studied the relationship between the value ofα and the properties of the spindle motor for the stator core 12 of thespindle motor of Embodiment 1 with different values of “α” which definesthe thickness of the bent portions 17 of the stator core sheet 12 a. Theresults are shown in FIGS. 7A through 7C.

FIGS. 7A through 7C are graphs in which a horizontal axis shows arotation angle of the hub 6 of the spindle motor according to thepresent invention and a vertical axis shows a torque. Curve a representschanges in a torque and curve b represents changes in a coggingcomponent. FIG. 7A is a graph where the value of α is about 0.9. Thereis a small distortion in a waveform showing changes in the torque andthere is a small amount of cogging component.

FIG. 7B is a graph when the value of α is 0.7. There is more distortionin the waveform showing torque changes and the cogging componentincreases. Preferably, the torque waveform is a sine wave and, ideally,no cogging waveform exists. However, as the spindle motor becomessmaller, there is less space for realizing a magnetic circuit designwhich satisfies ideal conditions. In practice, to include harmonic wavesto some extent is inevitable. In Embodiment 1, a of 0.7 or higher ispractically preferable. FIG. 7C is a graph where the value of α is about0.45. There is a large distortion in the waveform showing the torquechanges and a large cogging component. Thus, such a value is notpreferable. In this embodiment, a stator of a motor having a outerdiameter of φ 21 to 22 (mm), an inner diameter of φ 13 to 14 (mm), and athickness t of 0.7 to 0.8 (mm) was used. It was found that the sametendency is shown if a stator having an outer diameter of φ 17 to 18(mm) and an inner diameter of φ 9.5 to 10.5 (mm) is used.

In the spindle motor according to Embodiment 1, the stator core 12 isbent in bent portions 17 as shown in FIGS. 1 and 3. Thus, a gap betweenthe salient pole arm portions 14 and the base 4 becomes large.Therefore, the number of turns of the windings 10 wound around thestator core 12 can be increased. As a result, a large torque can beachieved. Also, the teeth portions 15 of the stator core 12 face thesurface of the rotor magnet 9 at right angles. Thus, the air gap betweenthe stator core and the rotor magnet is not expanded, and a magneticforce of the magnet can be effectively utilized. Further, in Embodiment1, the thickness of the stator core sheets 12 a which form the statorcore 12 is made thinner in bent portions 17. In this way, when aplurality of the stator core sheets 12 a formed using bend working usingone press mold are laminated, the stator core sheets 12 a can adhereclosely to each other without a gap being generated in the teethportions 15. Therefore, a noise due to vibration of the stator coresheets 12 a during operation is not produced. Deterioration of themagnetism property and increase in power loss due to the gap can also beprevented.

Embodiment 2

The spindle motor according to Embodiment 2 of the present inventionwill be described with reference to FIGS. 8 and 9. Embodiment 2 relatesto a spindle motor of an internal motor type. FIG. 8 is across-sectional view of the spindle motor. In FIG. 8, a base 34 which isa fixed portion of the spindle motor has a bearing support 34 a in itscentral portion and has a bearing unit 35 fixed to a hole of the bearingsupport 34 a. The bearing unit 35 supports a shaft 38 so as to berotatable. To the shaft 38, a hub 36 is attached. For example, amagnetic disc or an optical disc is attached to a disc receiving surface36 a of the hub 36. A rotor magnet 39 is attached to the hub 36.

A stator core 40 is provided on a support 34 b in an outer peripheralportion of the base 34. As shown in a plain view of FIG. 9A, the statorcore 40 includes nine salient pole arm portions 42 protruding from ayoke portion 43 having a ring shape in an inward direction. The spindlemotor is a motor with nine poles. Teeth portions (salient pole teethportions) 45 are integrally formed with respective inner peripheral endsof the salient pole arm portions 42.

The stator core 40 shown in FIG. 9A is formed by, for example,laminating stator core sheets 41 formed by punching thin plates of amagnetic material having a thickness of about 0.2 mm. FIG. 9B is across-sectional view of one of the stator core sheets 41 of the statorcore 40 cut along line IXb-IXb shown in FIG. 9A. As shown FIG. 9B, theteeth portions 45 are bent and tip portions of the teeth portions 45face a surface of the rotor magnet 39 substantially perpendicularly.

In the stator core sheets 41 of the spindle motor according toEmbodiment 2, as in the stator core sheet 12 a of Embodiment 1, theplate thickness of bent portions 44 of the stator core sheet 41 is madethinner than that of other portions. When it is assumed that thethickness of the other portions of the stator core sheets 41 is “t”, thethickness of the bent portions 44 a is α-t (α is a value within therange of 0.5 to 0.9). With this structure, it becomes possible toprevent a gap from being generated in the teeth portions 45 between thestator core sheets 41 adjacent to each other.

A conductor is wound around each of the salient pole arm portions 42 ofthe stator core 40 to form a winding 48. In the spindle motor accordingto Embodiment 2, well-known openings 33 (see, for example, JapaneseLaid-Open Utility Model Publication No. 62-168781) are provided in theportions of the base 34 which are below the windings 38. The windings 48are respectively wound around nine salient pole arm portions 42. Thus,nine openings 33 are provided. Nine windings 48 are connected as Yconnection or Δ connection in the case of a three phase motor.

In the spindle motor according to Embodiment 2 shown in FIG. 8, the bentportions 44 are provided in the stator core 40 and the teeth portions 45face the rotor magnet 39 at right angles. Further, the salient pole armportions 42 are located in a lower part of FIG. 8. Thus, the windings 48may be located in the lower part. As a result, it becomes possible tomake a distance between the disc receiving surface 36 a and the windings48 larger, and to reduce magnetic influence of the windings 48 on amagnetic disc to be attached to the disc receiving surface 36 a and amagnetic head seeking on the magnetic disc without compromising thetorque properties. Furthermore, by providing a magnetic shield plate 49having a ring shape on the windings 48, lines of magnetic force leakingout from the windings 48 can be blocked to significantly reduce magneticinfluence on a magnetic disc and the like. By providing openings inportions of the base 34 which faces the windings 48, the number of turnscan be increased to an extent that lower parts of the windings enter theopenings. With this structure, a larger torque can be obtained with aspindle motor which has a restriction on the dimension. In other words,a small and light spindle motor with a large torque can be realized.

In the case where a material of the base 34 is a non-magnetic material,an attractive plate 30 made of a magnetic material such as an iron plateis attached on a surface of the base 34 which faces the rotor magnet 39.With a magnetic force generated between the rotor magnet 39 and theattractive plate 30, it becomes possible to try to prevent positionalchanges of the hub in an axial direction due to positional changes ofthe motor.

A seal member 50 for blocking the openings 33 is adhered to a lowersurface of the base 34 in order to prevent foreign substances such asdust from entering the openings 33. A model number or the like of thespindle motor may be printed on the sealing member 50 so that it can beused as an inscription plate. In Embodiment 2, similar effects as thoseof the spindle motor of an external rotor type according to Embodiment 1can be achieved with a spindle motor of an internal rotor type.

Embodiment 3

A spindle motor according to Embodiment 3 of the present invention willbe described with reference to FIG. 10. Embodiment 3 relates to aspindle motor of an internal rotor type. The spindle motor has a statorcore 60 which has a different structure from that of the stator core 40of the spindle motor according to Embodiment 2 as shown in FIG. 8.However, other components are the same as those shown in FIG. 8.Therefore, elements same as those in FIG. 8 are denoted by the samereference numerals and overlapping explanation is omitted.

As shown in FIG. 10, the stator core 60 has a shape similar to that ofthe stator core 40 shown in FIG. 9A except for the shape around a yokeportion 63. A structure of the yoke portion 63 will be described belowin detail.

The stator core 60 is fixed to the base 34 with a lower end surface ofthe yoke portion 63 being supported by a supporting portion 34 bprovided on the base 34. A first bent portion 66 is formed between theyoke portion 63 and a salient pole arm portion 62. The first bentportion 66 has a similar shape as that of the bent portion 44 shown inFIG. 9B. The thickness of each of stator core sheets 61 forming thestator core 60 is made thinner in the first bent portion 66 than inother portions. The thickness of the first bent portion 66 isrepresented by “α-t”. α is a value within the range of 0.5 to 0.9. t isthe thickness of a stator core sheet 61.

A second bent portion 64 is provided between the salient pole armportion 62 and the teeth portion 65. The second bent portion 64 has ashape substantially similar to that of the second bent portion 44 ofEmbodiment 2 shown in FIG. 8.

In the spindle motor according to Embodiment 3 shown in FIG. 10, thefirst bent portion 66 and the second bent portion 64 are formed in thestator core 60. Thus, the salient pole arm portion 62 around which thewindings 68 are wound locates in a lower part of the figure.Specifically, as can be seen by comparing the stator core 60 shown inFIG. 10 to the stator core 40 shown in FIG. 8, a lower portion of thestator core 60 is in the openings 33 of the base 34 in FIG. 10. As thesalient pole arm portion 62 of the stator core 60 is brought close tothe base 34, a gap between an upper end surface 62 a of the salient polearm portion 62 and the magnetic shield plate 49 can be made larger. As aresult, the number of turns of the windings 68 wound around the salientpole arm portion 62 can be increased. In order to maximize the number ofturns of the windings 68, it is preferable to set bending angles of thefirst bent portion 66 and the second bent portion 64 such that thesalient pole arm portion 62 locates in approximately halfway between themagnetic shield plate 49 and the seal member 50. The dimension of thespindle motor of Embodiment 3 is substantially the same as the dimensionof the spindle motor of Embodiment 2. However, the spindle motoraccording to Embodiment 3 further includes a feature that the number ofturns of the windings 68 of the stator core 60 can be made larger thanthat of Embodiment 2 in addition to other features of the spindle motoraccording to Embodiment 2. Therefore, the spindle motor according toEmbodiment 3 can achieve a torque larger than that of the spindle motorof Embodiment 2.

The present invention is applicable to the spindle motors for rotatingmagnetic discs and optical discs.

1. A spindle motor comprising: a rotor magnet supported by ahydrodynamic bearing device so as to be rotatable; a stator core formedby laminating a plurality of magnetic material plates which have salientpole teeth portions facing the rotor magnet with a predetermined gapinterposed therebetween, salient pole arm portions which is connected tothe salient pole teeth portions, and a yoke portion connected to thesalient pole arm portions and fixed to a base; and windings wound atleast around the salient pole arm portions of the stator core, whereinthe plates of the magnetic material of the stator core has the salientpole teeth portions facing an opposing surface of the rotor magnetsubstantially perpendicularly, being bent at first bent portions betweenthe salient pole teeth portions and the salient pole arm portions suchthat the salient pole teeth portions and the salient pole arm portionsare substantially parallel, and a thickness of the first bent portionsof the plates is made thinner than that of other portions, and theplates are bent at second bent portions between the yoke portions andthe salient pole arm portions such that the yoke portion and the salientpole arm portions are substantially parallel, and a thickness of thesecond bent portions of the plates is made thinner than that of otherportions; and the plurality of magnetic material plates are laminatedsuch that gaps are generated above and below the first and second bentportions.
 2. A spindle motor according to claim 1, wherein therespective thicknesses of the first bent portions and the second bentportions of the plates of the stator core are within the range of 0.5times to 0.9 times that of other portions.
 3. A spindle motor accordingto claim 1, wherein the stator core is an external rotor type which isprovided on an inner peripheral side of the rotor magnet.
 4. A spindlemotor according to claim 1, wherein the stator core is an internal rotortype which is provided on an outer peripheral side of the rotor magnet.